[Vwdiesel] Calling all cars

[The Canadian Guitar Festival]

THis is a break down of the work done until now:

at 240 K the crank bolt breaks and the tooth in the in crank pulley which
drives the timing belt is sheared right off. There is no damage to the
crankshaft face. The head replacement and all the other points of
consequence resuting from this starting point are taken care of.
THe replacement crank bolt and crank pulley are purchased from the local VW
dealer and are genuine parts.
THe crank bolt is tightened to proper spec (66ft lbs etc)
The work is done by a liscenced mechanic.

3000 k later with the car running perfectly and without warning, the car
dies on the highway.

The lower pulley is nearly dislodged and is only loosely held in place by
the new timing belt which seems in perfect shape. Removal of the pulley
reveals that a portion of the bolt is still threaded into the crankshaft
while the tooth in the crank pulley looks as brand new as it did a month
ago.

THe bolt snapped and the crank pulley worked its way off the crankshaft to
the point where the keyway was no longer in sync and bingo...5 dollar bolt
causes 2500.00 + in damage.




> -----Original Message-----
> From: The Canadian Guitar Festival [mailto:vezco at cogeco.ca]
> Sent: May 16, 2006 2:58 AM
> To: Razvan Florea; info at canadianguitarfestival.com;
> Libbybapa at wmconnect.com
> Cc: vwdiesel at vwfans.com
> Subject: RE: [Vwdiesel] Calling all cars
>
>
> That's one..
>
> thanks :)
>
> Del
>
>
> > -----Original Message-----
> > From: Razvan Florea [mailto:florear at hotmail.com]
> > Sent: May 16, 2006 1:56 AM
> > To: info at canadianguitarfestival.com; Libbybapa at wmconnect.com
> > Cc: vwdiesel at vwfans.com
> > Subject: Re: [Vwdiesel] Calling all cars
> >
> >
> > Same problem here! Three times! It is only on 1,9 TD AAZ engine.
> > The mechanic replaced the toothed pulley and the bolt(which
> > elongates under
> > wrench tension and has to be replaced every time it is replaced) after
> > milling the face of the crankshaft with a special milling tool.
> > First time, no milling,  no new bolt, only new pulley, 3000 km
> > Second, crank milled, old bolt, second new pulley, 1800 km
> > Third, new bolt, pulley, milling special tool, 35.000 km since
> > with no more
> > problems. I hope!
> >
> >
> > ----- Original Message -----
> > From: "The Canadian Guitar Festival" <vezco at cogeco.ca>
> > To: <Libbybapa at wmconnect.com>
> > Cc: <vwdiesel at vwfans.com>
> > Sent: Tuesday, May 16, 2006 4:49 AM
> > Subject: Re: [Vwdiesel] Calling all cars
> >
> >
> > > Agreed...I spent $$$$ on a used head and labour as a result
> of this weak
> > > link in the chain at 240K
> > >
> > > A BRAND NEW bolt FROM THE DEALER less than TWO MONTHS LATER and under
> > > THREE
> > > THOUSDAND KILOMETERS that breaks and causes me $$$$ more in
> repairs is a
> > > major issue.
> > >
> > > thanks
> > >
> > > Del
> > >
> > >
> > >  -----Original Message-----
> > >  From: Libbybapa at wmconnect.com [mailto:Libbybapa at wmconnect.com]
> > >  Sent: May 15, 2006 9:37 PM
> > >  To: info at canadianguitarfestival.com; Diesel-Vanagon at yahoogroups.com
> > >  Cc: vwdiesel at vwfans.com
> > >  Subject: Re: [Vwdiesel] Calling all cars
> > >
> > >
> > >  In a message dated 5/15/06 4:39:42 PM US Mountain Standard Time,
> > > vezco at cogeco.ca writes:
> > >
> > >
> > >
> > >    I am asking everyone here in this group to speak to the
> > subject of the
> > >    nefarious crank bolt. If anyone has documentation or
> > anecdotal input to
> > > this
> > >    topic, please post to this group as there may be a basis
> for a class
> > > action.
> > >
> > >
> > >
> > >  I have never had a 1.9TD and so all that follows is hearsay.  So the
> > > crank
> > > nose and sprocket on the 1.9TD is the same as the 1.6TD, but
> > pulleys were
> > > changed along with the serpentine belt setup.  The setup had a
> > tendency to
> > > eventually wear out either the crank bolt or the keyway of
> the sprocket.
> > > The "fix" is to replace the crank sprocket with one from a TDI whick
> > > instead
> > > of the puny key has a "D" shape to it.  This requires that
> the crank be
> > > machined to accept the newer sprocket.  My understanding is
> > that the older
> > > version always fails eventually, and that the newer version
> does not.  I
> > > can't understand how you can hold a car manufacturer responsible for a
> > > problem after 200,000+ miles.  Possibly your mechanic for not
> > > reengineering
> > > what was a slightly better than mediocre original design, but not the
> > > original manufacturer?  200,000 is more than can be
> rationally expected.
> > > When it failed the second time it wasn't the original
> manufacturer that
> > > caused it to.
> > >
> > >  Andrew
> > >
> > >  Andrew
> > > _______________________________________________
> > > Vwdiesel mailing list
> > > Vwdiesel at vwfans.com
> > > http://www.audifans.com/mailman/listinfo/vwdiesel
> > >
>